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Introduction
Process plants worldwide often place considerable reliance on low-power solenoid valves. They are used as pilot valves to open and close larger ball or butterfly valves, or on control valves (installed between positioner and actuator) for fail-safe air release if theres a loss of power. They work by pressurizing or depressurizing associated actuators. A new generation of even lower-power valves is now changing the rules of the power consumption game. These products are of interest to designers working for original equipment manufacturers (OEMs) and valve assemblers, as well as for end-user engineers anyone who specifies solenoid valves for projects in refining, upstream oil and gas, chemicals, pharmaceuticals and life sciences, food and beverage, and power. This report taps the expertise of manufacturers at the forefront of low-power solenoid valve technology. It shows how innovation is offering new possibilities and challenges via topics such as integrated solutions, clogging and other reliability issues, usefulness in pointto-point and bus networks, other cost savings, remote applications, and relevant industry standards. Finally, it suggests which characteristics buyers should seek out in selecting the newest and most consistently dependable low-power valve technologies.
Safe (IS) valves. The IS valves, although operating at 0.5 watts, required costly IS safety barriers in the installation. Some end users realized that they could use IS valves in non IS applications at a greater power consumption of 1.5 watts. This offered them a power reduction compared to mid power valves, but they still faced limitations on flow and pressure. By about 1995, the performance level was improved by the introduction of a higher flow, higher pressure rating cartridge type valve that delivered acceptable performance at around a 1.5-watt rating. Lately, efforts toward even greater efficiency and energy conservation plus the popularity of bus networks and backup power schemes have increased downward pressure on the power curve. Designs are again approaching the magic half-watt mark, with the newest generation of truly low-power solenoid valves rated at 0.5 to 0.75 watt. However, not all low-powered valves are created equal.
ducted to ensure that the product would not fail in the field? What is the recommended maintenance schedule? What are its orifice size, pressure rating, reliability record, and other critical characteristics? How do these match the intended application?
So such valves particularly high-quality, stand-alone low-power solenoid valves rather than integrated solution models meet almost any real-world process requirements with ensured reliability. Buyers should check with the manufacturer for specific application suitability.
Point-to-point savings
Traditional point-to-point wiring schemes often incur greater expenses for a valves installation (labor, cables and conduits, fittings, connectors, I/O, and plant real estate) than for the valve itself. Solenoid valves configured around the emerging half-watt standard can reduce these installation costs. Their lower current draw eliminates the need for additional power isolation relays. They permit the use of smaller, less expensive wiring gauges. They also allow the use of downsized, less costly power supplies. In addition, power is a limiting factor in how many valves may be driven off a single PLC or DCS output card. Using valves that require only 0.5 watt to replace models drawing 1.5 watt, 1.8 watt, or more can double or triple each cards valve carrying capacity. Result: fewer output cards needed. So planners save on card purchase costs as well as on the costs of associated power supplies and/or batteries.
Remote possibilities
The new low-power solenoid valve models also present fresh opportunities for process control systems in remote locations. Examples include oil pipelines and remote gas extraction stations. There, planners must choose every device with an eye to minimizing power usage. Low-powered solenoid valves are an ideal fit. Designers of remote installations can choose from different savings paths. The lower power drain of the new valves can allow the system to be specified with a smaller battery bank. Alternatively, designers may hold batteries to the same size, but rely on decreased power consumption to optimize the system for longer operation without sunlight. Planners must also consider environmental needs. For instance, when the local temperature range includes extreme cold, standard low-power valves may require heat tracing or protection. This necessitates added power plus a larger, more costly battery/charging system. Instead, site designers should specify available low-power models rated for -40 F. Some less remote sites actually on the grid may still deploy backup power arrangements (generators or batteries). These locations include pharmaceutical lines and critical petrochemical lines where the loss of costly consumables, feedstocks, or in-process materials due to line interruption would be especially serious. The latest low-power solenoid valves help ensure less drain on these backups. Finally, the advent of SCADA systems has enabled monitoring of distant locations via remote terminal units. These communicate back to the production office, saving time and money and eliminating what once was routine onsite maintenance calls. Using the right high-reliability, low-power valves can prevent even more of these prohibitively expensive, time-consuming visits.
valves of this type promise to match the newest low-power technological capabilities with time-tested reliability.
Conclusion
Choosing low-power solenoid valves for process industry applications presents several challenges. Designers and users must carefully consider such issues as orifice size and clogging potential, pressure rating and other physical characteristics, bus compatibility, backup power needs, and relevant industry standards before selecting the right valve for the given process industry task. Fortunately, the newest generation of valves offers candidates that combine low power with reliable performance to suit more applications than ever before.
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